AEON MOTOR CO.,LTD
Contents
1. Remove the exhaust pipe bolts mounting on the frame below the rear fender Remove the exhaust pipe carefully 10 4 EXHAUST PIPE INSTALLATION Installation 1s the reverse order of removal Torque Exhaust bolts 30 N m 22 Ibs ft NOTE After installation check entire system to make sure that there are no exhaust leaks 80 11 ELECTRICAL SYSTEM 11 1 TROUBLESHOOTING 11 2 IGNITION COIL 11 3 IGNITION TIMING 11 4 ALTERNATOR EXCITER COIL 11 5 BATTERY CAUTION 11 6 BATTERY VOLTAGE 11 7 CHARGING 11 8 ELECTRIC STARTER 11 9 LIGHT BULBS REPLACEMENT 11 10 WIRING DIAGRAMS 11 1 Troubleshooting ENGINE STARTS BUT STOPS IMPROPER IGNITION TIMING FAULTY SPARK PLUG NO SPARK AT PLUG ENGINE STOP SWITCH AT LEFT OR RIGHT POSITION GEARSHIFT BAR IS NOT AT NEUTRAL POSITION FAULTY IGNITION COIL FAULTY GENERATOR FAULTY CDI UNIT POORLY CONNECTED Between CDI and ignition coil Between alternator and CDI unit Between CDI and engine stop switch Between ignition coil and spark plug Between generator and CDI unit ENGINE STARTS BUT RUNS IGNITION PRIMARY CIRCUIT POORLY Faulty generator Faulty CDI unit Faulty alternator Loosen contacted terminals Faulty ignition coil IGNITION SECONDARY CIRCUIT Faulty plug Loosen contacted spark plug wire IMPROPER IGNITION TIMING 81 Faulty generator Faulty CDI unit CHARGING SYSTEM FAILURE LOOSE BROKEN OR SHORTED WIRE FAULTY ALTERNATOR FAULTY IGNITION SWITCH INTERMITTENT ENGI2. L ILELEFFFFEFE IHR Hd ux i UNAM IM al The engine number is stamped under the crankcase 1 5 TORQUE VALUES STANDARD 5mm bolt and nut 6mm bolt and nut bolt and nut 10mm bolt and nut 12mm bolt and nut ENGINE Cylinder head nut Spark plug Cylinder head bolt Alternator bolt FRAME Handlebar upper holder bolt Throttle housing cover screw Steering shaft nut Steering shaft holder bolt Wheel rim bolt Tie rod lock nut King pin nut Handlebar lower holder nut Front wheel bolt Front axle nut Front brake arm nut Rear brake arm nut Rear axle nut Rear wheel bolt Exhaust muffler mounting bolt Engine hanger bolt Rear axle holder bolt Swingarm pivot nut Rear shock absorber mounting nut 5 N m 3 5 Ibs ft 10 7 2 1565 10 22 N m 16 lbs ft 35 N m 25 Ibs ft 55 N m 40 Ibs ft 28 N m 20 7 Ibs ft 12 N m 8 9 Ibs ft 20 N m 14 8 Ibs ft 8 N m 5 9 Ibs ft 24 N m 17 7 Ibs ft 4 N m 2 9 lbs ft 50 N m 36 9 Ibs ft 33 N m 24 Ibs ft 18 N m 13 3 Ibs ft 35 N m 25 8 lbs ft 40 N m 29 Ibs ft 40 N m 29 5 Ibs ft 24 N m 17 7 Ibs ft 60 44 lbs ft 4 N m 3 0 Ibs ft 7 5 2 Ibs ft 60 44 3 Ibs ft 24 N m 17 7 Ibs ft 30 N m 22 1 5 30 N m 22 Ibs ft 90 N m 65 Ibs ft 90 65 Ibs ft 45 N m 33 Ibs ft 2 Maintenance 2 1 Maintenance data 2 2 Maintenance schedule 2 3 Fuel tube 2 4 Throttle operation 2 9 Throttle c
3. 12 STEERING SYSTEM Check the free play of the steering shaft with the front wheels turned straight ahead When there 1s excessive play inspect the tie rod kingpin bushing and ball joint Steering shaft holder bushing Remove the front fender Remove the steering shaft holder and check the steering shaft bushing for wears or damage If the bushing is worn or damaged change a new one Grease the steering shaft bushing and install the parts in the reverse order of removal Torque steering shaft holder bolt 33N m 24 Ft 165 13 2 13 TOE IN Park the vehicle on level ground with the front wheels facing straight ahead Mark the centers of the tires to indicate the axle center height Measure the distance between the marks Carefully move the vehicle back let the wheels turn 180 so the marks on the tires are aligned with the axle center height Measure the distance between the marks Calculate the difference the front and rear measurements Toe in 5410 mm If the toe in is out of standard adjust it by changing the length of the tie rods equally by turning the tie rod while holding the ball joint Tighten the lock nuts Torque 35 43 N m 14 2 14 GEAR OIL MAINTENANCE Gear oil needs to be changed every 200 hours There is a gear oil drain hole bolt at the rear of the engine STEPI Unscrew this drain hole bolt and let the dirty oil flow out catching the oil in a proper contain
4. CAPACITY 1 2 liter at draining OIL DRAIN Install the oil filter cap Install the oil level gauge Start the engine and let it idling for 2 or 3 minutes Stop the engine and check that the oil level at the upper line on the gauge Make sure there are no oil leaks FAN COVER ASS Y odi 2 u 4 5 OIL PUMP REMOVAL Remove the fan cover ass Remove the cooling fan composition COOLING FAN COMPOSITION 20 Remove the A C G generator ass y Remove the left crankcase cover Remove the starting clutch outer and gear ass y Remove the flange bolts and oil separator CRANKCASE COVER STARTING CLUTCH OUTER STARTING CLUTCH GEAR MG OIL SEPARATOR ie FLANGE BOLTS 21 Remove the oil pump chain and oil pump driven OIL PUMP CHAIN sprocket PUMP DRIVEN SPROCKET Remove the oil pump ass y OIL PUMP ASSY Disassemble the oil pump INSPECTION OL PUMP BODY p ER ee IR Measure the oil pump rotor to body clearance SERVICE LIMIT 0 12 mm Install the oil pump shaft and measure the pump SEHE rotor tip clearance SERVICE LIMMIT 0 12 mm UPS OIL PUMP SHAFT Remove the oil pump shaft and measure the pump and clearance OIL PUMP OUTER ROTER SERVICE LIMMIT 0 2 mm 2 PUMP INNER ROTER 4 5 OIL PUMP ASS Y INSTALLATION Install the outer roto
5. Engine and exhaust pipe become very hot and remain hot for one hour after the engine is run Wear insulated gloves before handling these parts USED ENGINE GEAR OIL Used engine oil and gear oil may cause skin disease after repeated contact with the skin for long periods Keep out of reach of children 1 2 NOTES information illustrations directions and specifications included in this publication are base on the latest product information available at the time of approval for printing No part of this publication may be reproduced without written permission 1 3 SPECIFICATION ENGINE CHASSIS SUSPENSION BRAKES TIRES Specifications subject to change without notice Displacement Bore and Stroke Compression Maximum Power Carburetor Ignition Starting Lubrication Air Cleaner Transmission Overall Length Overall Width Overall Height Wheel Base Dry Weight Fuel Tank Capacity Front Rear Front Rear Front Rear 180 Air Cooled 4 syroke with Oil Cooler 169 cc 61x57 8mm 9 1 1 6 2 Nn 96300 min MIKUNI 180 C D I Electronic Electrical amp Kick Start Wet crankcase with lobes pump AE 9 Automatic C V T system 1790mm 970mm 1200mm 1050mm 156kg 8 0 liter Double wishbone Swing Arm Drum Disc 242 x 7T 2 10 29 x 10 8 1 4 SERIAL NUMBER The frame serial number is stamped on the front frame And stick a bar code paper to cover it
6. Starter motor will not turn Engine stop switch at left or right position Gearshift bar 1s not at neutral position Check for a blown fuse near battery Make sure that the battery 1s fully charged and in good condition 84 11 9 LIGHT BULBS REPLACEMENT Remove inside two bolts on both sides of the head light cover Remove the headlight bulb and position light Remove the position light bulb Change the new one and install to the headlight seat Press and turn left to remove the bulb 85 Change a new bulb and reinstall Install the bulb seat to headlight seat Tighten inside two bolts TAIL LIGHT Remove taillight lens by removing the two nuts Replace taillight lens and secure with two nuts 86 11 10 WIRING DIAGRAMS 87 12 TROUBLE SHOOTING 12 1 Engine does not start 12 2 Poor Performance at low and idle speed 12 3 Poor Performance at high speed 12 4 Loss of power 12 5 Poor handling 12 1 Engine does not start N G Check Fuel Flow to Carburetor Spark Test N G Weak or No Spark N G Cylinder Compression Test Low Compression N G Start The Engine Engine starts Stops N G Remove spark Plug Wet plug And Inspect 88 Possible Causes No fuel in fuel tank Clogged float valve Clogged fuel tank cap breather hole Faulty Spark Plug Fouled spark Plug Faulty CDI unit Faulty Alternator Faulty engine stop switch Poor connection Bro
7. splashing oil when operating 74 A A r s 1 3 STEP 5 Install the rear brake cable fixing set amp adjust the brake cable 1 Spin the gap adjuster on the left lever till the shortest position 2 Adjust the adjusting screw and keep the gap being 2 3 mm Fr nt Rear Brake ergneprake 3i 00 Ratio Distribution Balance AdjUSime nia al STEP 6 Wire Connector Adjustment 1 The distribution of front rear brake force on left lever 75 2 The balance adjustment of left right front brake STEP 7 The brake balance adjuster on right lever 76 9 4 DRIVE MECHNISM Removal and inspection Remove the rear wheel and the rear brake Remove the skid plate under swing arm Remove the drive chain cover Er i uy m d ML qu n 1 T d E m mE Disassemble the chain retaining clips mas ter link Remove the chain Disassemble the driven sprocket axle and sprocket collar Check the driven sprocket for damage or wear Replace if necessary Let the rear axle lie 1n V blocks and check the runout The runout limit 1 0 5 mm Check the turning of inner race of bearing with T1 fingers The bearings should turn smoothly and quietly Replace if necessary Also check that the bearing outer race fits tightly in the axle holder Replace if necessary NOTE Replace the bearings in pairs
8. 0 030 0 057 0 10 EX 1 0 1 8 TORQUE VALUES Cylinder head bolts 9 12 N m 5 9 8 9 Ibs ft Camshaft holder flange nuts 20 24 14 8 17 8 Ibs ft Tappet adjusting nut 9 12 n m 6 6 8 9 Ibs ft 26 5 2 TROUBLE SHOOTING Engine top end problems usually affect engine performance These problems can be diagnosed by a compression test or by tracing engine noise to the top end with a sounding rod or stethoscope Low compression valve Incorrect valve adjustment Worn or damaged valve seats Burned or bent valve Incorrect valve timing Weak valve spring Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Faulty cylinder or piston Excessive noise Incorrect valve adjustment Sticking valve or broken valve spring Worn or damaged rocker arm or camshaft Worn or damaged cam chain Worn or damaged cam chain tensioner Worn cam sprocket teeth Excessive smoke Damaged valve stem seal Faulty cylinder or piston rings 21 5 3 CAM SHAFT ASS Y REMOVAL Remove the rubber tube of gas waste recovery 1 s 2 un gt X ooo GAS WASTE RECOVERY Remove the cylinder head cover Remove the air cleaner and carburetor Remove the inlet pipe ass y Remove the shroud compositions SHROUD COMPOSITIONS Relax the cam chain adjuster screw CAM CHAIN ADJUSTER SCREW 28 Remove the screw and O ring and tighten the C
9. 65 10 Tappet adjusting nut 9 12 N m 6 6 8 9 Ibs ft 37 6 2 TROUBLESHOOTING Low or unstable compression Worn cylinder or piston rings Overheating Excessive carbon build up on piston or combustion chamber wall Knocking or abnormal noise Worn piston and cylinder Excessive carbon build up Excessive smoke Worn cylinder piston or piston rings Improper installation of piston rings Scored or scratched piston or cylinder wall Damaged valve stem seal 38 6 3 CYLINDER REMOVAL Remove the cylinder head Remove the cylinder 2 CYLINDER 3 A m m m Porra Li mullum cmi us m Remove the cylinder gasket and dowel pins Clean off any gasket materials from the cylinder surface NOTE Be carefully not to damage the gasket surface 39 6 4 PISTON REMOVAL Stuff a shop towel into the crankcase Remove the piston pin clip with needle nose pliers NOTE Do not allow the clip fall into the crankcase Remove the piston pin from the piston Remove the piston POM EE PISTON PIN Spread each piston ring and remove it by lifting up at a point opposite the gap E NEIN INSPECTION Inspect the cylinder walls for scratches or wear m m m 40 Measure and record the cylinder I D at three levels in both an X and Y axis Take the maximum reading to the cylinder wear SERVICE LIMITS 0 10 mm Calc
10. ACER 57 ASSIDE PISTON INSTALLATION Install the piston with it s IN mark on the intake valve Install the piston pin with new pin clips Do not align the piston pin clip end gap with the piston cutout NOTE do not allow the clip to fall into the crankcase 6 6 CYLINDER INSTALLATION Clean any gasket material from the crankcase surface NOTE Be carefully not to damage the gasket surface Install the dowel pins a new gasket 44 Coat the cylinder bore and piston rings with engine oil and install the cylinder NOTE Avoid piston rings damage cylinder bore during installation Do not allow the cam chain fall into the crankcase Install the cylinder head 45 7 TRANSMISSION amp KICK STARTER 7 1 SERVUCE INFORMATION 7 2 TROUBLE SHOOTING 7 3 C V T DISASSEMBLY 7 4 KICK STARTER DISASSEMBLY 7 5 KICK STARTER ASSEMBLY 7 6 C V T ASSEMBLY 7 1 SERVICE INFORMATION If the drain tube ass y fills with water the tube should be drained SPECIFICATIONS Clutch weight tining CS TORQUE VALUES Clutch outer nut 55 N m 40 6 Ibs ft Drive face nut 55 N m 40 6 Ibs ft 46 7 2 TROUBLE SHOOTING Engine starts but can t travel Worn driven belt Worn clutch lining Damaged driven face spring Low engine power Worn driven belt Worn weight roller Dirty driven face 47 7 3 C V T DISASSEMBLY LH CRANKCASE COVER REMOVAL Relax the band screw and rem
11. AEON MOTOR CO LTD OVERLAND 125 180 SERVICE MANUAL CONTENTS 1 2 2 2 6 3 ENGINE REMOVAL AND INSTALLATION 16 4 ENGINE LUBRICATION AND COOLING SYSTEM 7 5 CYLINDER HEAD amp 26 CYLINDER amp e 37 7 TRANSMISSION 46 FRONT WHEEL SUSPENSION AND STEERING 57 68 10 FENDERS AND EXHAUST 79 11 ELECTRICAL SYSTEM mee 81 12 TROUBLE 5 2 0202 88 1 INFORMATION 1 1 Safety 1 2 Notes 1 3 Specifications 1 4 Serial number 1 5 Torque valve 1 1 Safety GASOLINE Gasoline 15 extremely flammable and 1 explosive under certain condition Do not smoke or allow sparks or flames in your work area CARBON MONOXIDE Never run the engine in a closed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death BATTERY ELECTROLYTE The battery electrolyte contains sulfuric acid Protect your eyes skin and clothing If you come into contact with the electrolyte flush the area thoroughly with water If you get the electrolyte in your eyes flush with water and contact a doctor immediately HOT PARTS
12. AM CHAIN ADJUSTING 1 cam chain adjusting bolt with clockwise direction Remove the nuts and washers Remove the camshaft holder and dowel pins Relax the camshaft gear from cam chain and remove the camshaft INSPECTION Inspect the cam lobes surface and height of cam lobes for wear or damage SERVICE LIMIT 25 57 26 18 mm 25 41 26 02 mm 29 Inspect the camshaft and bearings for wear or damage and replace them if necessary Screw a5 mm bolt into the rocker arm shaft threaded end Pull on the bolt to remove the shafts and rocker arms Inspect the camshaft holder rocker arms and rocker arm shafts for wear or damage Measure the I D of each rocker arm SERVICE LIMIT 10 10 mm Measure the O D of each rocker arm shaft SERVICE LIMIT 9 91 mm BEARINGS E m m a BCX KER ARMS ROCKER ARM SHAFTS 30 5 4 CYLINDER HEAD REMOVAL Remove the flange bolts and cylinder head Remove the cylinder head gasket and dowel pins Remove the cam chain guide CYLINDER HEAD DISASSEMBLY Remove the valve cotters spring retainers and valve springs with a valve spring compressor 3l INSPECTION Clean off all carbon deposits from the com bustion and check the spark plug hole and valve area for cracks Measure the cylinder head diagonally for warp with a straight edge and feeler gauge T Measure the free length of the inner and outer valve
13. Brake lining oily greasy or dirty Improper brake adjustment FRONT SUSPENSION Loose front suspension fastener Binding suspension link HARD SUSPENSION Faulty front swing arm bushing Improperly installed front swing arms Bent front shock absorber swing rod SOFT SUSPENSION Wear front shock absorber springs Worn or damage front swing arm bushing 59 8 5 HANDLEBAR SYSTEM Removal Remove the handlebar cover by unscrew two fix SCICWS Remove the throttle lever housing on the right handlebar Remove brake lever bracket Fe Te LU assembly Remove the handlebar switch on the left handle bar Remove rear brake lever bracket ass y Remove the bolts attaching the handlebar upper holder Remove the handlebar 60 Installation Install the switch housing Tighten two screws securely Install the throttle lever housing and brake lever bracket ass y 61 8 4 THROTTLE HOUSING Disassembly Unscrew the screws on the throttle housing Remove throttle housing cover and gasket Disconnect throttle cable from the throttle arm and remove from the throttle housing Assembly is in the reverse order of disassembly 8 5 FRONT WHEEL Remove Raise the front wheels off the ground by placing a Jack or other support under the frame Remove the front wheel nuts washer and wheels Installation Install and tighten the four wheel nuts torque 60 N m 44 Ibs ft Reme
14. ICE LIMIT 23 92 mm z rin 1 Ea mi iT AET jaulas av d Br Inspect the clutch outer for wear or damage Measure the I D of clutch outer I SERVICE LIMIT 125 5 mm Inspect the clutch weight set for wear or damage Measure the thickness of clutch weight lining SERVICE LIMIT 1 5mm 51 Measure the length of driven face spring SERVICE LIMIT 164 0 mm DRIVEN FACE SPRING mei mm Rn cum Inspect the driven face ass y and replace them if necessary 7 4 KICK STARTER DISASSEMBLY Remove the LH crankcase cover KICK STARTER CRANKCAS E COVER m Remove the kick starter Remove the ex Circle clip and washer from kick starter spindle composition 52 Remove the kick starter spindle ass y ISTARTER SPINDLE ASS Y ey i i Remove the kick starter idle gear ass y Remove the kick spindle bush INSPECTION Inspect the kick starter spindle composition for wear or damage Inspect the kick starter return spring for fatigue or damage KICK SPINDLE BUSH Inspect the kick starter spindle bush for wear of damage KICK RETURN SPRING Inspect the kick driven gear and spring for wear damage KICK DRIVEN SPRING 53 7 5 KICK STARTER ASSEMBLY Install the kick driven gear and spring Install the kick spindle bush return spring a
15. IONS Engine Oil Capacity 0 8 1 0 Liters Engine Oil Recommendations Viscosity SAE 15W 40 API Service classification SF SG 17 OIL PUMP STANDARD SERVIC LIMIT Cover to rotor clearance 0 12 Rotor tip clearance 0 12 End clearance 0 01 0 10 0 2 TORQUE VALUE Oil Drain Bolt 20 30 14 8 22 1 Ibs ft 4 2 THROTTLE SHOOTING Oil level too low high oil consumption Normal oil consumption External oil leaks Oil not changed often enough Worn piston rings Faulty heat gasket Oil contamination Worn piston rings Faulty heat gasket Oil or filter not changed often enough 4 3 ENGINE OIL LEVEL Place the engine on the level plane Check the oil level with the oil level gauge but do not screw it in when making this check Gy LEVEL GL 18 4 3 ENGINE OIL LEVEL Add the recommended oil up to the upper level if the oil level is below or near lower level line on the gauge LOWER LEVEL UPPER LEVEL 4 4 ENGINE OIL amp FILTER CHANGE Remove the oil filter cap and the oil drain bolt NOTE drain the oil while the engine is warm to 1 ensure complete draining Remove the oil filter cap spring and oil filter SCICCD Check the O ring for damage or fatigue Install a new oil filter screen and spring then install the cap 19 Install the oil drain bolt with sealing washer TORQUE 20 30 14 8 22 1 Ibs ft Fill the crankcase with recommended oil ENGINE OIL
16. Installation Add grease to the dust seal lips and install dust seals Assemble the rear axle and the driven sprocket Assemble the drive chains on the driven sprock et Assemble the master link and retaining clip NOTE The retaining clip direction Install the drive chain cover Assemble the chain under cover Install the skid plate Install the drive chain cover 78 10 FENDER AND EXHAUST PIPE 10 1 REAR FENDER REMOVAL Pull the Seat Release Bar to take off the seat This seat release bar is under the right side of the rear fender Procedure for rear fender removal Remove the rear rack and seat Unscrew the four bolts which connect the front fender and rear fender Unscrew the four screws which connect the rear fender and frame Unscrew the six screws which connect with footrest plate Pull the rear fender backward so the rear fender can be removed 10 2 FRONT FENDER REMOVAL After remove the rear fender remove the two front fender mounting bolts from front frame Remove the fuel tank cap 79 Remove the mounting bolts and nuts from the front fender and footrest plate 10 3 EXHAUST PIPE REMOVAL You must wait at least 15 minutes after turn off the engine You need to remove the seat rear fender and footrest plate before you take off the exhaust pipe Unscrew the two exhaust pipe bolts that fixed with engine NOTE Do not service the exhaust pipe while they are hot
17. NE POWER LOOSE BATTERY CONNECTION LOOSE CHARGING SYSTEM CONNECTION STARTER MOTOR WILL NOT TURN DEAD BATTERY FAULTY IGNITION SWITCH LOOSE OR DISCONNECTED WIRE STARTER MOTOR AND ENGINE TURN FAULTY IGNITION SYSTEM BUT ENGINE DOES NOT START FAULTY ENGINE STOP SWITCH ENGINE PROBLEMS HEAD LIGHT DO NOT WORK THE SWITCH DO NOT PUSH TO THE ON POSITION THE LIGHT BULB IS BURN OUT NEED BE 11 2 IGNITION COIL Remove the spark plug cap from the spark plug Disconnect the 1gnition coil primary wire Measure the primary coil resistance STANDARD 0 1 0 300 Measure the secondary coil resistance with the spark plug cap in place STANDARD 7 4 11 11 3 IGNITION TIMING The ignition advance is 13 H 4000rpm The capacitive discharge ignition CDI system is factory pre set and does not require adjustment 82 11 4 ALTERNATOR EXCITER COIL Remove the seat rear fender and front fender see page 72 disconnect the exciter coil wire Measure the resistance between the yellow or white or green wire and ground STANDARD 467 7000 Electrolyte is poisonous Drink large quantities of water or milk and call a physician if swallowed 11 5 BATTERY CAUTION The battery gives off explosive gases keep sparks flames and cigarettes away Provide adequate ventilation when charging or using the battery in an open area The battery contains sulfuric acid electrolyte Contact with skin or eyes may cause severe burns Wear p
18. TEM Remove the kingpin and Tie rod Remove the front wheels and brakes plates Remove the four self lock nuts from the tie rod ball joints and take off the two tie rods Remove the cotter pin on the kingpin Unscrew the bolt and remove the kingpin Tie rod inspection Inspect the tie rod for damage or bending Inspect the ball joint rubbers for damage wear or deterioration Turn the ball joints with fingers The ball joints should turn smoothly and quietly Kingpin inspection Inspect the kingpin for damage or cracks 65 Steering shaft removal Remove the handle bar cover and handle bar see page 58 Remove the front fender see page 72 Remove handlebar lower holder Unscrew steering shaft holder bolt remove steering shaft holder Take off the cotter pin below steering shaft Unscrew the steering shaft fix out below shaft Pull steering shaft carefully Steering shaft holder inspection Remove the steering shaft Remove the bushing from the shaft Inspect the bushing for damage or wear replace if necessary Measure the bushing inner diameter Maximum limit 039 5 mm Steering shaft inspection Inspect the steering shaft for damage or cracks Installation of steering shaft Apply grease to the holder Install the holder and oil seal tighten with the nuts Torque 33 N m 24 Ibs ft 66 8 7 STEERING SYSTEM Installation of steering shaft Install the steering shaft nut and tighten
19. a wire type feeler eauge and adjust 1f necessary by carefully bending the side electrode SPARK PLUG GAP 0 6 0 7 mm m CENTER ELECTBDIE RECOMMENDED REPLACEMENT PLUG obi 1 2 d 1 6 CR7HSA IN WEAR 6 Check the sealing washer and replace with a i new one if damaged 7 With the sealing washer attached thread the SEAL TN bon spark plug in by hand to prevent cross CHECK RACKS 1 threading Tighten the spark plug TORQUE 12 19 N m 2 5 IDLE SPEED SETTING 1 Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specifications The engine must be warm for accurate idle speed inspection and adjustment 2 Warm up the engine for about ten minutes and connect a tachometer 3 Turn the throttle stop screw as required to obtain the specified 1dle speed IDLE SPEED 1700 100 rpm 10 2 9 DRIVE CHAIN ADJUSTMENT Stop ATV and shift transmission into neutral Inspect the chain slack midway between the sprockets The standard 1 10 25 mm 5 8 1 inch If needed remove the chain protective cover and adjust the chain slack Loosen the axle holder lock nut then adjust the drive chain slack by turning the adjusting nut Tighten the axle holder lock nut Torque 90N m 65 Ft Ibs When the drive chain becomes very dirty it should be removed cleaned and lubricated with the specifi
20. able adjustment 2 6 Air cleaner 2 4 Spark plug 2 8 Idle speed 2 9 Drive chain 2 10 Brake system 2 11 Wheels and tires 2 12 Steering system 2 13 Toe in 2 14 Gear oil 2 1 MAINTENANCE DATA SPECIFICATION SPARK PLUG Spark plug cap Recommended spark plugs Throttle lever free play Idle speed Brake lever free play Drive chain slack Front rear tire size Front rear tire pressure Toe in TORQUE VALUES SPARK PLUG TIE ROD LOCK NUT ENGINE OIL Viscosity GEAR LUBRICATION OIL Viscosity 0 6 0 7mm NGK C7HSA or CR7HSA 5 10mm 1800rpm 10 20mm 15 25mm 21 X 10 2210 8 3 46 3psi 0 15 kgf cm 59 12 19 35 43 N m SAE 15W 40 SAE 85W 140 2 2 MAINTENANCE SCHEDULE The maintenance intervals in the follow table is based upon average riding condition Riding in usually dusty areas require more frequent servicing Service Item Initial Service Every 100 hours Every 200 hours Every 300 hours First 30 hours ENGINE OIL GEAR OIL FUEL FILTER AIR VLEAN FILTER ENGINE OIL FILTER SPARK PLUG VALVE GAP IGNITION TIMING THROTTLE OPERATE TIRE Check before riding each time PRESSURE BRAKE Check before riding each time SYSTEM A Adjust Clean Inspection R Replace T Tighten 2 5 FUEL TUBE Inspect the fuel lines for deterioration damage or leakage and replace if necessary 2 4 THROTTLE OPERATION Inspect for smooth lever operation full opening and automatic f
21. ed lubricant Clean the drive chain with kerosene and wipe it dry Inspect the drive chain for possible wear or damage Replace the chain if it is worn excessively or damaged Inspect the sprocket teeth if it has excessive wear or damage replace if needed Use a commercial chain lubricant to lubricate the drive chain replace and adjust the slack as described above 2 10 BRAKE SYSTEM ADJUSTMENT Inspect the front brake lever and cable for excessive play or other damage Replace or repair if necessary Measure the free play of the brake lever at the end of the lever The standard is 10 20 mm Adjust the free play of the front brake lever by turning the adjuster on the brake lever assembly Inspect the rear brake lever and cable for excessive play or other damage Replace or repair 1f necessary Measure the free play of the brake lever at the end of the lever The standard 1 10 20 mm Adjust the free play of the rear brake lever by turning the adjuster on the rear axle BRAKE SHOE WEAR Front Brake Release the front wheel and inspect the brake lining thickness Service Limit 2 0mm 0 08 inch if either lining is worn beyond the service limit replace both brakes shoes 12 2 11 WHEELS AND TIRES Inspect the tire surface for cuts nails or other sharp objects Check the tire pressure at cold tire conditions The standard tire pressure 1 3psi 0 15kgf cm 2
22. er for later disposal STEP2 Reinstall the drain hole bolt an tightness STEP3 Fill with new gear oil through the oil fill hole located on the engine case beside the gear box 15 oil Drain Bek 3 1 ENGINE REMOVAL AND INSTALLATION ENGINE SHOULD ONLY BE REMOVED IN THE CONDITIONS OF NECESSARY REPAIRS OR ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM ONLY 3 2 ENGINE REMOVAL Remove the front rear rack and handle bar Remove the footrest Remove the spark plug cap from the spark plug Remove the exhaust muffler Disconnect the carburetor cable by unscrew two screws on top of the carburetor Disconnect the wire connectors There are three connectors for carburetor auto choke starter motor and generator respectively Remove the engine hanger bolts over the engine Remove the engine and air cleaner together 3 2 ENGINE REPLACEMENT Engine installation 15 essentially the reverse order of removal The torque of engine hanger bolt is 30 Nm Route the wires and cable properly in reverse order of removal 16 4 LUBRICATION 4 1 Service Information 4 2 Trouble Shooting 4 3 Engine Oil Level 4 4 Engine Oil amp Filter Change 4 5 Oil Pump Removal Installation 4 1 SERVICE INFORMATION GENERAL This section describes inspection and replacement of the engine oil oil filter screen and assembly of the oil pump Fill the oil pump with clean oil when reassembling the pump SPECIFICAT
23. he camshaft gear with cam chain so that its I mark aligns with the cylinder head surface and the circle hole towards the front Install the dowel pins and camshaft holder Tighten the washers and nuts Torque 20 N m 14 8 Ibs ft Adjust the clearance between the rocker arm and valve stem by applying a feeler gauge STANDARD VALVE 0 08 mm Relax the cam chain adjusting bolt with coun terclockwise direction and install the o ring and SCICW 35 Install the cylinder head cover CYLINDER HEAD COVER a F Bhi I 1 L EP i Weer i m 80 a L i i T f a 36 6 CYLINDER AND PISTON 6 1 SERVICE INFORMATION 6 2 TROUBLESHOOTING 6 3 CYLINDER REMOVAL 6 4 PISTON REMOVAL 6 5 CYLINDER INSTALLATION 6 1 SERVICE INFORMATION GENERAL Camshaft lubrication oil 1 fed to the cylinder head through an oil orifice in the cylinder head and engine case Before installing the cylinder head be sure the orifice is not clogged and the gasket O ring and dowel pins are in place SPECIFICATION 52 400 52 410 61 730 61 740 61 700 61 720 61 63 Prostar mam o wm ww ore Cranes TOMEC as sas a TORQUE VALUES Cylinder head bolts 9 12 N m 5 9 8 9 Ibs ft Camshaft holder flange nuts 20 24 N m 14 8 17 7 15
24. ide O 02 Possible Causes Damaged steering bearing Damaged steering shaft bushing Bent steering shaft Bent rim Improperly installed wheel hub Excessive wheel bearing play Bent swing arm Bent frame Excessive wear of swing arm bushing Bent Axle Bent tie rod Incorrect tie rod adjustment Rear tire pressure incorrect Improper wheel alignment Bent frame
25. ide Brake Lever Blake Lever 70 Caliper 71 The Brake Adjustment Phillips Bolts 93100 05016 K Plain Washer 94101 0514010 K Nylon Lock Nut 90350 05000 K xX 10 sets Ae STEP 1 Take off the right side footwell for adjustment 72 Rear Brake Gelale Fixint amp Set 73 STEP The setup of the adjusting nut of the brake pump 1 The brake pedal should be in the highest location under the function of the returning spring 2 The adjusting nut changes the distance between the brake pump and the hydraulic cylinder driving rod Make the nut touch the surface of the rod and revolve 1 circle 360 then confirm the nut location and spin the rod till the nut is locked 3 Notice If adjust the nut over 1 circle it might result in the brake pump malfunction and jam the brake STEP 4 Drain the air in the brake oil tube in order to prevent the brake pump malfunction in power delivering 1 Open the brake oil tank lose the drain screw of the brake caliper without braking motion It functions normal if the brake oil could drain automatically please try this for couple times for confirmation If it doesn t work please be back to STEP 3 and decrease the distance until the oil could run out normally 2 Press on the brake pedal or the brake lever for several times then hold press release the drain screw and lock it on immediately until no air bubble in the brake oil Be careful for the
26. it This nut is under this steering shaft Torque 50 37 Ibs ft Installation of Tie rod Install the tie rod on the wheel side Installation 1s 1n the reverse order of removal 67 9 REAR WHEEL SYSTEM 9 1 PARTS DRAWING 9 2 TROUBLESHOOTING 9 3 REMOVE REAR WHEEL AND REAR BRAKE 9 4 DRIVE MECHNISM 9 5 REAR BRAKE AND WHEEL INSTALLATION 9 1 Parts Drawings 9 2 Troubleshooting 68 Bad Brake Performance Brake shoes are worn Bad brake adjustment Brake lining are oily greasy or dirty Brake drums are worn Brake arm setting 1s improperly engage Vibration or wobble Axle is not tightened well Bent rim Axle bearings are worn Faulty tires Rear axle bearing holder is fault Brake Drag Incorrect brake adjustment Sticking brake cam Sticking brake cable Faulty swing arm pivot bushing Wear shock absorber spring 9 3 REMOVE REAR WHEEL amp REAR BRAKE Loosen the cotter pin and wheel nuts raise the rear wheel off the ground by placing a support under the frame Release the wheel and wheel hub Brake Parts amp Location LL 4 Handlebar Rear Brake Cable Front Brake Front Brake Cable 2 Front Brake Foot Brake Hydraulic Cylinder Driving Rod Wire Brake Pump Connector i Hear Brake Caliper RearBrakeOi Tube Brake Oil Tube 69 Rod The cable Brake LeftSide Right S
27. ken or shorted wires Broken or shorted ignition coil Worn cylinder and or piston rings Damaged cylinder head gasket Auto choke off or damaged Auto choke power wire disconnected Improper adjustment of air screw Carburetor flooded Improper adjustment of air screw Fuel Air mixture ratio to rich Auto choke stuck or damaged Air cleaner dirty Check Ignition Timing N G Check Carburetor and Air Screw Adjustment Check for intake pipe leak N G N G Preform Spark Weak or Intermittent Plug Test Spark 89 Possible Causes Faulty CDI Unit or Pulse generator Improper Air Screw adjustment Deteriorated insulator O Ring Loose or disconnected ignition system wires Faulty spark plug carbon fouled or wet Faulty alternator Faulty CDI unit Faulty ignition switch Faulty ignition coil Faulty pulse generator Broken or shorted spark plug wire Faulty engine stop switch 12 3 Poor performance at high speed NG Possible cause Check Ignition Timing Faulty CDI unit or Pulse generator Check Fuel Flow to Carburetor NN C AP Lack of fuel in tank Fuel Flow Clogged fuel line Restricted Clogged fuel valve O Clogged fuel filter Clogged fuel tank breather hose Remove Carburetor check N G for clogged jets clogged Clean jets with high pressure air gun O N G Check Air CI Repl ean or Replace air clean elemen Clean Element Dirty 90 12 4 Loose
28. mber put a cotter pin in the castle nut 8 6 FRONT BRAKES Front brake inspection Remove the front wheel Remove the brake drum Measure the brake lining thickness The minimum limit 1 5 mm If they are thinner than the minimum limit replace the brake lining 62 Measure the brake drum inner diameter The maximum limit 111 mm Turn the inner race of each bearing with fingers The bearings should turn smoothly and quietly If the race does not turn smoothly or quietly remove and discard the bearings Brake panel removal Disconnect the brake cable from the brake arm Remove the brake panel from the knuckle Remove brake arm and cam Remove return spring Remove indicator plate and felt seal Install Brake panel Apply grease to the brake cam and anchor pin and install the cam in the brake panel Soak the felt seal in the engine oil and install the seal on the brake cam Install the brake arm on the cam by aligning the punch mark and the groove on the cam Tighten the brake arm bolt and nut Torque 4 7 N m Install the return spring Install the brake panel on the knuckle Connect the brake cable to the brake arm Install the brake arm cover Tighten the screws securely Position the brake shoes in their original locations and install the brake shoe spring Install the brake drum and front wheel Install the castle nut and cotter pin 64 8 7 STEERING SYS
29. nd spindle ass y Install the kick starter 7 6 C V T ASSEMBLY Assemble the driven face ass y spring and driven plate a 1 KO KICK STARTER 7 5 2 54 Assemble the movable drive face weight roller set and drive face Install the movable drive face ass y and boss DRIVE FACE BOSS 7 E P MOVABLE DRIVEN Install the drive face and kick starter ratchet Install the driven belt and driven pulley ass y 55 Install the dowel pins and gasket Install the LH crankcase cover Install the air cleaner case and C V T ducts 56 8 FRONT WHEEL SUPENSION AND STEERING 8 1 PARTS DRAWING 8 2 TROUBLESHOOTING 8 3 HANDLEBAR 8 4 THROTTLE HOUSING 8 5 FRONT WHEEL 8 6 FRONT BRAKES 8 7 STEERING SYSTEM 8 8 FRONT SUSPENSION 8 1 PARTS DRAWING 27 58 8 2 TROUBLESHOOTING HARD STEERING Faulty tire Steering shaft holder too tight Insufficient tire pressure Faulty steering shaft bushing Damaged steering shaft bushing FRONT WHEEL WOBBLING Faulty tire Worn front brake drum bearing Bent rim Axle nut not tightened properly BRAKE DRAG Incorrect brake adjustment Sticking brake cable STEERS TO ONE SIDE Bent tie rods Wheel installed incorrectly Unequal tire pressure Bent frame Worn swing arm pivot bushing Incorrect wheel alignment POOR BRAKE PERFORMANCE Brake shoes worn Worn brake drum
30. of power Raise wheels off of N G ground and Spin by hand Does not spin freely N G Check Tire Pressure Low tire pressure OK Accelerate Lightly N G Engine speed does Not increase Check Ignition N G Timing Test Cylinder N G Compression Low pressure Check N G Carburetor Clogged Check Spark N G Plug Fouled or Discolored Check for Engine N G Overheating Overheating Accelerate or Run at High Knocks Speed 91 Brake dragging Adjust brake Drive chain too tight Damaged wheel bearing Wheel bearings need lubricated Punctured tire Faulty tire pressure value Fuel Air mixture ratio to rich or lean Clogged air cleaner element Clogged exhaust muffler Fuel flow restriction Lack of fuel in tank Clogged fuel valve Clogged fuel filter Clogged fuel tank breather hose Faulty CDI unit Faulty pulse generator Leaking head gasket Worn Cylinder and or piston rings Clean fuel jets Clean float valve Clean Re gap spark plug Faulty spark plug Spark plug is incorrect heat range Wrong fuel type Fuel Air Ratio mixture to lean Use of poor quality or old fuel Excessive carbon deposits in combustion chamber Worn piston and or cylinder Fuel Air Mixture ratio to lean Wrong fuel type Ignition timing to advanced Excessive carbon deposits in combustion chamber 12 5 Poor Handing Steering feels heavy N G One wheel is wobbling N G N G Vehicle pulls to one s
31. ove the C V T inlet duct Remove the air cleaner case Wr LI mi Aa us pun yi 9 r E LE I 5 L1 _ i E mg i x T dh 5 z j AIR CLEANER CASE Remove the bolts and LH crankcase cover 48 Remove the gasket and dowel pins E d a L NLN JLH CRANKCASE SURFACE REMOVAL Relax the flange nut and remove the drive face Relax the flange nut Remove the drive pulley ass y and driven belt Remove the drive face boss and movable driven face ass y MOVABLE DRIVEN FACE a eens dul 49 Remove the ramp plate and weight roller set __ WEIGHT ROLLER SET Relax the special nut and remove the driven plate composition and driven face spring SPECIAL NUT INSPECTION Inspect the driven belt for wear tears or damage Measure the width of driven belt SERVICE LIMIT 19 0 mm DRIVEN BELT Inspect the weight roller for wear or damage and replace them if necessary Measure the O D of weight rollers SERVICE LIMIT 14 6 16 6 mm m s 50 Measure the I D of movable driven face SERVICE LIMIT 28 03mm Inspect the drive face collar for wear or damage Measure the I D of drive face collar SERVICE LIMIT 24 098 mm Inspect the drive face boss for wear or damage Measure the O D of drive face boss SERV
32. r inner rotor and oil pump shaft onto the body NOTE Pour a drop of clean engine oil inside the oil pump Install the oil pump 23 Install the oil pump driven sprocket and oil pump chain Install the oil separator DEFIE Oll SEPARATOR Install the starting clutch outer and gear ass y Install the new gasket dowel pins and right crankcase cover 24 Install the A C G generator ass y ACG GENERATOR ASST EDT a is E Install cooling fan composition Install fan cover 22 5 CYLINDER HEAD VALVES 5 1 SERVICE INFORMATION 5 2 TROUBLESHOOTING 5 3 CAMSHAFT ASS Y REMOVAL 5 4 CYLINDER HEAD REMOVAL 5 5 CYLINDER HEAD INSTALLATION 5 1 SERVICE INFORMATION GENERAL This section describes the maintenance of cylinder head valves camshaft and the other parts The engine must be removed from the frame to service cylinder head Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the engine case Before installing the cylinder head be sure the orifice 1s not clogged and the gasket O ring and dowel pins are in place SPECIFICATIONS J STANDARD SERVICE LIMIT Cylinder compression 12205kg m EX 25 810 27 20 25 40 26 80 RockrarmLD 1000010008 1010 Rocker arm shaft O D 92997 91 Valve spring free length IN 32 3 31 2 EX 35 0 34 1 EX 4 955 4 970 4 90 EX
33. rotective clothing and a face shield Electrolyte is poisonous Drink large quantities of water or milk and call a physician if swallowed 11 6 BATTERY VOLTAGE INSPECTION Battery is under the seat you can see this battery after removing the seat Measure the battery voltage using a voltmeter VOLTAGE Fully charged 13 1 V Undercharged Below 12 0 V BATTERY REMOVAL Remove the seat then you can see the battery Disconnect the negative cable and then the position cable and remove the battery BATTERY INSTALLATION Install the battery in the reverse order of removal After installing the battery terminals with clean grease 83 11 7 CHARGING Connect the charge positive cable to the battery positive terminal Connect the charge negative cable to the battery negative terminal Using 0 9A charging current about 5 hours Normal charging Or using 4A charging current about 1 hour Quick charging Keep flames and spark away from a battery being charged Quick charging should be limited to an emergency normal charging 15 preferred 11 8 ELECTRIC STARTER Information A weak battery may be unable run the starter motor quickly enough If the battery voltage 1s enough while the engine is not cranking the starter motor may be damaged Troubleshooting Starter motor turns slowly Weak battery Poorly connected starter motor cable Faulty starter motor Poorly connected battery ground cable
34. springs SERVICE LIMITS Inner 31 2 mm Outer 34 mm E VALVE EC Inspect each valve for turning burning scratches or abnormal stems wear Check the valve movement in the guide prm VALVE 32 Measure and record each valve stem O D SERVICE LIMITS 4 90 mm Measure and record the valve guide I D SERVICE LIMITS IN EX 5 30 mm Calculate the stem to guide clearance SERVICE LIMITS IN 0 08 mm EX 0 10 mm NOTE If the stem to guide clearance exceeds the service limits determine if a new guide with standard dimensions would bring the clearance within tolerance If so replace guides as necessary and ream to fit If the valve guide 1 replaced the valve seat must be refaced CYLINDER HEAD ASS Y Lubricate each valve stem with oil Insert the valves into the guides Install the valve springs retainers and the cotters NOTE To prevent loss of tension don t compress the valve springs more than necessary INSTALLATION Install the new gasket and dowel pins 33 Install the cam chain guide Install the cylinder head CAMSHAFT ASS Y INSTALLATION Install the rocker arms and rocker arm shafts into the camshaft holder Align the mark on the flywheel with the index mark on the alternator cover by turning the flywheel counter clockwise 34 UYLINIMZR HPA i 7 P p q a ET B u E E Position t
35. ulate cylinder taper at three levels in an X and Y axis Take the maximum reading to determine the out of round SERVICE LIMITS 0 10 mm Inspect the top of the cylinder for warp SERVICE LIMITS 0 10 mm PISTON PISTON RING INSPECTION Measure the piston ring to groove clearance SERVICE LIMITS 0 12 mm SECOND 0 12 mm 4 D IN lt 3 TOP 4 MIDDLE BOT FOM Inspect the piston for wear or damage m Insert each piston ring into the cylinder and measure the ring end gap NOTE Push the rings into the cylinder with the top of the piston to be sure they are squarely set in the cylinder SERVICE LIMITS TOP 0 5 mm SECOND 0 5 mm zal m mz mm mu mm n mu mH ms ca Uma DN UC Measure the piston pin O D SERVICE LIMIT 14 960 mm PISTON PIN Measure the piston pin O D SERVICE LIMIT 15 04 mm 42 Calculate the piston to piston pin clearance SERVICE LIMITS 0 02 mm Measure the connecting rod small end I D SERVICE LIMITS 15 06 mm 6 5 PISTON amp PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston ring with the marks facing up NOTE Don t interchange the top and second rings Avoid piston and piston ring damage during installation Space the piston ring end gaps 120 degrees apart 43 LG u mi um cm ma um cm Um um mw DA m as 7 ae oP PAF SECOND me se SIDE RAIL SP
36. ull closing in steering positions Inspect for deterioration damage cuts and nicks or kink in the throttle cable replace it if necessary Check the throttle lever free play should be not more than 5 10 mm at the tip of the throttle lever Disconnect the throttle cable at the upper end Lubricate the cable with commercially lubricant to prevent premature wear 2 5 THROTTLE CABLE ADJUSTMENT Slide the rubber cap of the adjuster off the throttle housing loosen the lock nut and adjust the free play of the throttle lever by turning the adjuster on the throttle housing Inspect the free play of the throttle lever Throttle Cable Adjuster 2 6 AIR CLEANER MAINTENANCE 1 Loosen the screw and remove the air cleaner from carburetor 2 Disassemble the air cleaner cover and body 3 Remove the air cleaner element and screen 4 Install the new one 5 Assemble the air cleaner body and cover and re attach to the carburetor with screw 2 7 SPARK PLUG The spark plug is located at the front of the engine 1 Disconnect the spark plug cap and remove the spark plug 2 Visually inspect the spark plug electrode for wear or cranks in insulator Replace if needed 3 The center electrode should have square edges and the side electrode should have a constant thickness 4 Discard the spark plug if there 1s apparent wear or if the insulator 1s cracked or chipped 5 Measure the gap with
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